Coated construction material and method of making the same



R. P. PERRY. COATED CONSTRUCTION MATERIAL AND METHOD OF MAKING T IIE SAME.

APPLICATION FILED OCT. 9. 1917. 1,869,187, Patented Feb. 22, 1921.

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,4 TTORNEY RAY I. PERRY, OF UPPER MONTCLAIR, NEW JERSEY, ASSIGNOR T0 THE BARRETT I COMPANY, A. CORPORATION 0F NEW JERSEY.

coa'rnzo ooiisTnUcTroN MATERIAL AND METHOD or MAKING THE sar/rn f essaies.

To all wko/m t may concern: Be it known that l, RAY P. PERRY, a citi- Zen of the United States, residing at Upper Montclair, in the county of Essex and State of New Jersey, have invented certain new and useful improvements in Coated Construction Materials and Methods of Making the Same, of which the following is a specification.

' In my co-'pending application entitled Construction materials and processes of' producing the same, filed October 9,1917, and bearing Serial No. 195,655, I have described and claimed a dry felt having special advantages when intended to be saturated, and the process of making such felt; also a process of saturating the previously referred to dry felt, and the resulting saturated felt.

. My present invention relates to a constructibn material, such as the so-called rubber roofings of commerce, consisting generally of d felt or simil-ar basesa-turated with water-. proofing material and covered with a protective coating of waterproofing material, suoli as asphalt, and Ito a process of making such material, wherein l employ a saturated felt of the sort described' and claimed in my copending application above. This felt consists of a sheet of porous felt or paper having a plurality of depressions on one or both sides of the same. Preferably the depressions areof a predetermined cubical content and the depressions on each side are staggered with relation to each other. Where the depressions are provided on'both sides of the sheet they may preferably be staggered, not merely with relation to each other on each side of ythe sheet, but such depressions may preferably also be staggered relation to the depressions on the side of the sheet.

lVhile this felt is described in my co-pending application as being embossed before it is saturated, l may, in the present instance, emboss the felt after it has been saturated. The saturated felt is generally in a somewhat moist, impressionable condition, due to the presence of the saturating material in the sameand the saturated felt is, therefore,

,capable of receiving and retaining the desired depressions.

However prepared, the saturated felt, having the aforesaid depressions, preferably of predetermined content, on one or both sides Specification of Letters Patent. Patglltggd Fqgbn Application filed October 9, 1917.v Serial No. 195,656. h

of the same, is coated with any desired weatherproofing material, such as-asphalt,

for example. The depressions are preferablystaggered with relationy 'to each other. The coating material fills the depressions, and thereby becomes fixed or locked in the depressions. The outer face of the coating,

or of the coatings, where bo-th sides are coated may be -smooth or have the usual alligator finish. As a result of this construction and mode of procedure, a coated construction material is provided in which' portions of the coating material, generally of predetermined amount, are fixed or locked in the depressions provided in the saturated felt. This locking of portions from peeling away from the saturated felt p base, and in this way the lifeof the conof the coating materia-l prevents the same Referring to the drawing wherein l'. have illustrated two species of the product of my invention, Figure 1 shows in side elevation, and Fig.

Fig. 4' isa similar view olf still anotherv modification.

B indicates the base of |the construction material, consisting generally of a sheet of f 8;@ 2 shows in pla-n view a strip of constructionv felt orvpaper saturatedwith waterproofing material, such as asphalt, for example. The sheet B is provided with the depressions 2, 2 defined bythe raised portions 1, 1. While the exact form of the depressions is generally immaterial, I prefer to provide the same with sloping sides as indicated, and to make the same of substantially rectangular formation. As shown in Fig. 2 the d ressions are staggered with respect to each other, this arrangement of the depressions serving to lock the coating material more securely in place than where the depressions are arranged in straight lines. As previously stated, the depressions may be made in the felt after the same has been saturated. After the saturated felt has been provided with the depressions, which are preferably of predetermined cubical content, the coating material C is `applied to that side of the base B. i '-.In' Fig. 3 I 1oA drawing, with the result -that portions 3, 3 of the coating material fill the.l depressions 2, 2 and thereby serve. to` securely Afix or..

lock the coating' C in place: uponV the of ,weatherproofing material. In this species the base B consists o f a sheet of felt lor paper saturated with waterproofing ma-v terial, such as asphalt, and provided on one raised portions 4,' 4 and .on the other' side with the depressions 8, 8 defined by the raised portions 7, 7. Preferably the depres` sions 5 are staggered with `relation to each v other, as are also the depressions 8,8. I

prefer also to stagger the depressions 5,- 5. not merely with relation to each other, but with relation also to the depressions 8, 8.

v,After the strip of saturated felt B has rel.ceived the aforesaid depressions, the coatlngs C and C are applied to the two surfaces thereof, the coating material consisting generally of a weatherprooiing material such as-asphalt. The coating C will, in this way, be provided with the portions 6, 6 which will be fixed or locked in the depressions 5, 5, while the 'coating C will havethe portions 9, 9 fixed or locked in the depressions 8, 8. In this way the coatings Cand Cwill be securely fixed in position upon the base B and a construction material of superior wearing qualities will thereby result.

In Fig. 4 I have illustrated a species of'l my invention wherein the depressions 10 are 1n the form of channels of predeter-v mined cubical content extending substantially (or, if desired, entirely) across the' width of the sheet B, the depressions being defined by the raised transverse portions 1l, l1, and the raised edge portions 12, l2.

What I claim is:

1. The process of producing a lconstruction material, which comprises the steps of providing a sheet of felt saturated with waterproofing material, forming a plurality of depressions on at least one side thereof in such a manner thatthe respective portions of the surface opposite said depressions are left substantially undistorted, and thereafter coating the side provided withithe depressions with a layer of protective weatherproofing material, whereby portions of the' coating material will be fixed -in the said depressions.

2. The process of producing a`construction material, which comprises the steps of providing a sheet of felt saturated with Waterproofing material, forming a plurality `of depressions on each Side thereof 1n such a manner that the respective portions of' the surface opposite said depressions are left substantiall undistorted, aand thereafter coating eac side provided with the ldepressions' with a layer of protective'weatherv` proofing material, whereby portions of the coating material will rbe fixed in the said depressions. l

3. The process of'producing a construc- 'tion material, which comprises the steps of providing a sheet of felt saturated with waterproofing material, forming a pluralityof staggered depressions on at least one side A thereof, and thereafter coatingthe side pro side with thedepressions 5, 5 defined by the y vided with the depressions with a layer ofA protective weatherproofing material, where by portions of the coating material will be'4 fixed in the said depressions.

'4.' The process'of producing aconstruc# tions of the surface opposite said depressions are left substantially undistorted,`a'nd thereafter coating each side provided with the depressions with a 4layer 'of protective weatherproofing material, whereby portions of the coating material will vbe fixed in the said depressions.

5. The process of producing a construction material, which comprises the step-s of providing a. sheet'of felt saturated with wa-y terproofing material, forming a plurality of depressions of predetermined cubical content on at least one side thereof in such a manner that the` respective' portions of the surface opposite said depressions are' left substantially undistorted, and thereafter coating the side provided with the depres-` sions with a layer of protective weatherproofing material, whereby portions ofthe coating material will be fixed in the depressions. l

6. The process of producing a construction material, which comprises the steps of providing a sheet of felt saturated with waterproofing material, forming a plurality said of staggereddepressions of predetermined cubical content on each side thereof in such a manner that thevrespective portions of the' surface opposite said depressions are left substantially undistorted, and thereafter coating each side provided with the depres sions with a layer of protective weatherproofing material, whereby portions of thefv coating material will be-fixed in the said de ressions.

The process of producing a construction material which comprises the steps of providing a sheet of felt saturated with wa terproofing material, forming depressions i depressions, whereby the ycoatin therein so that the distance from the bot-- tom of said depressions to the opposite side of the sheet is less than the average thickvnessof the sheet, and thereafter coating the 'sheet with a layer of protective weather-, proofing material, whereby coating material will 1 f pressions.

portions of the L ,8. A construction material comprising a `sheet of felt saturated with'waterprooing material and having a plurality of depressions on at least one side thereof formed in such a manner that the respective portions i of the surfaceopposite said depressions are 'i5 substantially undistorted, anda protective coating of 4weatherprooing materialbnat least 'that side of the sheet having the said material has portions thereof located and Xed within the said depressions.

9. A construction material comprising a sheet offelt saturated with waterproofing material and having a plurality of depres' sions on" at lea-st one, side thereof formed in such a manner that the respective portions of the surface opposite said depressions are substantially undistorted, and a protective y coating of weatherproofing material on -at least that side of the sheet having the said depressions, whereby the coating material has portions thereof located and fixed wit`nin the said depressions, the outer face of the coating being substantially unindented.

. 10. A construction material comprising a sheet of felt saturated with waterproofing materialv and having a plurality of depressions of predetermined cubical content on be fixed in the said dejl ,tions thereof located an at lleast one side thereof'formed in such a manner that the respective portions of the surface opposite said depressions are substantially `undistorted, and a protective vcoating of weatherproofing material on at least i lthat side of thel Sheet having the said depressions, whereby the coating material has v 45 portions thereof located and fixed within the said depressions. 'y

11. A construction material comprising a l 4 sheet of felt saturated with waterproofing material and having a plurality of staggered depressions of predetermined cubical content on at least one sidet'hereof formed in such a manner that vthe-respective portions of the surface oppositesaid depressions are sub'- Astantially undisto'rted, and a protective coating of weatherproofing material on atleast that side of the sheet having the said depressions, whereby the coatin material has porsaid depressions.

i. l2. `A.. construction material-coniprisin a fixed withinl the n feo sheet of felt saturated with waterproo ng materia-l and having a plurality of Adepresc sions on at least oneside thereof, the bot- In testimony whereof I aiiix my signature. l

RAYPPERRY, 

